MAD DA2002 Instruction Manual
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MAD DA2002 Instruction Manual

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DA2002
1
en
DA2002
Instruction Manual
English
MAD Disc Aligner
20-02-2015
TH2250040

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Summary of Contents for MAD DA2002

  • Page 1 DA2002 DA2002 Instruction Manual English MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 2: Table Of Contents

    11.2 Spare Parts 12. Electrical Diagram 13. Technical Specification 14. CE-declaration of conformity 15. Disposal instructions 16. Guarantee Read and follow this instruction manual before assembling, installing, operating, or servicing the equipment. Original instructions Version: 08 TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 3: Summary

    DA2002 Summary Summary DU2010 Drive Unit DL2002 Lathe Storage Box Fig. 1 MAD Disc Aligner 20-02-2015 TH2250040...
  • Page 4 E. Brush F. S-hook G. Cable H. Safety cover I. Oil J. Hex T-spanner K. Tool for cable working height L. Cylinder 12.5x10 M. Cylinder 12.5x20 N. Tool bits Screws M2.5 O. Conical ring Fig. 2 TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 5 Inserts without thread Ø9 mm / 0.35 inch Ø10.5 mm / 0.39 inch Ø12.5 mm / 0.47 inch Inserts with thread M10 (metric) Washers Ø24xØ11x4 / 0.94x0.43x0.16 in Bolts M10x25 (metric) M10x30 (metric) M10x40 (metric) MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 6: Important Safety Instructions

    27. Always follow the safety regulations and the (dis-)assembly instructions provided by the car manufacturer when (dis-)assembling vehicle parts. 28. A 0.5 meter (20 inch) working area is required both next to the drive unit DU2010 and next to the disc lathe DL2002. TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 7 35. If possible, always use the rubber silencer ring on the outer edge of the brake disc. This will minimize vibration and/or noise. 36. MAD cannot be held liable for customized attachments or modifications of the equip- ment. 37. Prior to using the equipment, damaged safety guards or other parts should be checked in order to ascertain that they still function properly.

  • Page 8: First Installation

    DA2002 Important Safety Instructions First Installation Box 1 Fig. 7 Tighten 80Nm M12x30 Fig. 8 19mm Fig. 9 TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 9 Box 3 Install alumi- num tube through motor unit and then bolt to bottom Pull plate. bracket Box 2 Pull bracket Box 1 Fig. 11 Fig. 10 4 bolts M10x35 Tighten 50Nm 17mm Fig. 12 MAD Disc Aligner 20-02-2015 TH2250040...
  • Page 10 DA2002 Important Safety Instructions Attach cable to clip Fig. 13 Nut M6 Nut M6 10mm Washer Fig. 14 Washer Bolt M6x30 TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 11 DA2002 Important Safety Instructions Using hand grip, push motor unit down to ap- proximate height of box. Fig. 15 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 12: Controls Dl2002 Lathe

    6. 36V power plug 7. Handle 8. << and >> Slides high-speed control buttons 9. < and > Slides low-speed control buttons 10. Autofeed 2 - Slides high-speed automatic feed 11. Autofeed 1 - Slides low-speed automatic feed TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 13: Controls Du2010 Drive Unit

    Direction / stop switch Speed adjuster Drive yoke Safety cover Power inlet 36V outlet Fig. 17 Use this hand grip to roll cart Use this hand grip along shop to reposition height floor. of drive motor. Fig. 18 MAD Disc Aligner 20-02-2015 TH2250040...
  • Page 14 The drive unit is reset by rotating the motor switch to position 0. Fig. 19 Fig. 20 Rotate bottom ring clockwise to reset Press down for emergency stop. emergency stop. Rotate direction switch to 0 to reset drive unit. Fig. 21 Lock caster wheels during machining. TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 15 Fig. 23 Fig. 24 Fig. 25 160 - 155 rpm 130 rpm When using a two-post car Maximum torque, use lift, gradually adjust motor on 4WD cars. speed to reduce vehicle sway. Fig. 26 Fig. 27 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 16: Preparation

    DA2002 Preparation Preparation Fig. 29 Fig. 28 Fig. 30 Fig. 31 Fig. 32 Fig. 33 TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 17 << or >> on the control panel. The green LED of the Lathe should be on. 24. In this position the tool bits cannot be damaged by touching the brake disc. MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 18: Fitting Mounting Adapter

    With thread Use inserts without thread, in the correct size: Ø16.2 mm / 0.63 inch (without insert) Ø9.0 mm / 0.35 inch Ø10.5mm / 0.39 inch Fig. 36 Ø12.5 mm / 0.47 inch Fig. 37 TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 19: Choice Of Z-Brackets

    Lathe Vehicle Fig. 39 In some cases it may be neces- sary to go between short and long: Medium adapt- Vehicle Vehicle Use z-brackets 39 and 42 or: 40 and 41 Fig. 41 Fig. 40 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 20: Adapter Assembly

    Ensure the slide piece hex head bolts are loose. 5. Position the slide piece in the center of Fig. 44 the hub. Then hand tighten the UMA mounting adapter M10 bolts, Fig. 44. TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 21: Fitting The Dl2002 Lathe On Uma

    Mounting adapter hex-head bolts: torque to 25 Nm (18 Ft-Lbs). 9. Verify the brake disc rotates freely with no parts dragging or coming in contact with other parts. O.K. Fig. 45 Fig. 47 Fig. 46 Fig. 48 Fig. 49 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 22: Examples

    DA2002 Fitting DL2002 Lathe on UMA Examples Adapter with short z-brackets and with M10 metric insert, on hub with normal disc size. Fig. 50 Fig. 51 Fig. 52 TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 23 DA2002 Fitting DL2002 Lathe on UMA Adapter with long z-brackets and with M10 metric insert, on hub with large disc size. Fig. 54 Fig. 53 Fig. 55 MAD Disc Aligner 20-02-2015 TH2250040...
  • Page 24 DA2002 Fitting DL2002 Lathe on UMA Adapter with short z-brackets and with insert without thread, on hub with normal disc size. Fig. 56 Fig. 57 Fig. 58 TH2250040 20-02-2015 MAD Disc Aligner...
  • Page 25 DA2002 Fitting DL2002 Lathe on UMA Adapter with long z-brackets and with insert without thread, on hub with large disc size. Fig. 59 Fig. 60 Fig. 61 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 26: Positioning Du2010 Drive Unit

    6. Check that the brake disc is free to rotate, with no parts dragging or blocking. 7. NOTE: The drive shaft and brake disc on the other side of the vehicle could start turning when the lathe drive unit is turned on. 5 mm 0.2 in Fig. 62 TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 27: Machining

    17. Check that the brake disc is not machined thinner than the specified replace- ment size indicated in the repair manual. If the brake disc is thinner than al- lowed, the disc must be replaced. >click< Fig. 64 Fig. 63 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 28: Follow-Up

    20. Tighten the wheel nuts/bolts to the specified torque setting. 21. Check the brake fluid level and top off the fluid level as specified in repair manual. Fig. 65 Fig. 66 Fig. 67 Fig. 68 TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 29: Maintenance

    When reinstalling the bit holder, point the slot to- ward the outside of the Lathe D. On a weekly schedule, inspect cables and extension cables for damage and im- mediately replace them as necessary. Phillips PH1 Fig. 70 Fig. 69 Fig. 71 MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 30: Troubleshooting

    - In the event of an electrical failure, temporary operation of the slides is possible by first inserting a 6mm Allen wrench in the hole in the back plate and turning the screw with the wrench. TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 31: Tips / Spare Parts

    - Replacement parts can be ordered through your supplier. When ordering parts, refer to the parts list included with the lathe. Please provide the lathe serial num- ber when ordering. - Store this instruction manual and parts list in the storage box of the Lathe. MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 32: Electrical Diagram

    DA2002 Electrical Diagram Electrical Diagram Fig. 72 TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 33: Technical Specification

    (79 - 197 microinch) Brake disc surface roughness Ra 1.0 - 2.0 μm (39 - 79 microinch) Noise level, excluding a space 74 dB(A) correction factor of 4 dB(A) (NEN-ISO 11204 en ISO 3746) Tab.2. MAD Disc Aligner 20-02-2015 TH2250040...

  • Page 34: Ce-Declaration Of Conformity

    Some collection points accept products free of charge. We apologize for any inconvenience caused by minor inconsistencies in these in- structions, which may occur as a result of product improvement and development. TH2250040 20-02-2015 MAD Disc Aligner...

  • Page 35: Guarantee

    4. The date on which this guarantee comes into effect is determined by the date of its delivery to the end-user; the date shown on the MAD dealer’s invoice is defini- tive. 5. All parts that are subject to wear-and-tear are excluded from the guarantee, as are components/products that are explicitly supplied under different guarantee condi- tions.
  • Page 36 DA2002 MAD Holding B.V. P.O. Box 760 3900 AT Veenendaal The Netherlands T (+31)318 586 100 F (+31)318 541 213 E info@mad-tooling.com I http://www.mad-tooling.com TH2250040 20-02-2015 MAD Disc Aligner...

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